Features

Achieve Total Control

What would it be like to be in total control? Imagine saving at least 1.8% of your yearly ingredient costs. What would that be worth to you?

Picture having an extra supervisor watching over your employees’ shoulders monitoring and controlling the formulation process. What effect would that have on your product consistency and production efficiency?

Doran’s FC6300 Formula Control System puts you in total control and can pay for itself in just four months or less

Field-Proven Ingredient Savings

In today’s competitive marketplace, reducing production costs is a sure path to greater profits. Doran’s Formula Control has been guiding production plants along that path with ingredient savings of at least 1.8% - even more. Combine lower ingredient costs with the elimination of the money wasted on bad batches and you can understand why successful companies are investing in the FC6300 Formula Control System.

Take a look at the savings one company experienced with the FC6300. This plant realized that improving the performance of their formula scaling could lead to a significant impact on profitability. Additionally, they were averaging one bad batch a week due to errors that were traced back to the scaling process. They turned to Doran Scales to provide the solution to reduce costs from wasted ingredients and bad batches - that solution was the FC6300 Formula Control System.

Return on investment due to ingredient cost savings was achieved in just four months and the net one year effect on profit margin was $27,068.71. It’s no wonder that plant managers at this company’s other location suddenly became interested in the FC6300 Formula Control System.

Consistent Batches - Guaranteed!

Reduction of ingredient costs is easy to see, but the costs associated with bad batches are often overlooked. Like a dripping faucet, those bad batches can drain your plant’s profits a little at a time. Production downtime to clean production lines, discard the bad batch, along with cost of wasted ingredients can add up. Our field studies show that bad batches cost a company $837 per incident. With guaranteed consistent batches, your plant will run more efficiently - adding to your profitably.

By prompting the user through the formula, the correct ingredients are accurately scaled every time. Each ingredient of the formula is weighed within a tolerance that you define. The color-coded Accu-Track display on the bright LCD screen ensures ingredients being added are within those tolerances. Each step of the formula is clearly labeled with batch ID, batch name, the step number, ingredient name, target weight and actual weight. Accurate scaling can be achieved with or without experienced production employees.

Ensures Employee Accountability

Formula Loader is a standard component of the FC6300 Formula Control system. This Windows compatible software is used to configure formulas as well as to provide production reports. Standard Formula Loader reports can be used to evaluate scale operator efficiency and ingredient usage. Using scale operator ID’s, the FC6300 tracks when a user logs in and out of the scale. Management can easily determine how long the scale operators are taking to prepare each formula and how accurately it was done. It’s like having the plant manager watching over your employees’ shoulders 24/7.

Fast, Accurate, and Easy Lot Traceability

Scaled formulas are saved as a digital record, far more accurate than the typical hand written records used on most plant floors today. The digital format makes searching and analyzing production data fast and accurate. With a click of a mouse button, all batch data of a specific lot ID can be retrieved

View critical QC data in real time.
QC Weigh allows you to observe plant-wide quality control data from a single PC. Control limits are color-coded so you can quickly identify issues in your production processes.

Quality control data that you can trust.
Data is digital and stored in a database for retrieval - eliminating unreliable, handwritten records. Scale operators are prompted to take samples at intervals that you specify.

Easy to configure and use.
QC Weigh is a Windows compatible program that features drop-down menus that are clear and concise. With little effort, you’ll be experiencing the cost savings benefits

View Critical Quality Control Data in Real Time
Reducing cost of poor quality begins with actionable data delivered quickly and accurately. QC Weigh software achieves that by capturing quality control data as it is taken and transmits the data to your desktop. Using dropdown menus, you can fi lter the data by several different variables; a few of those variables are date range, product id, product line, and workstation. On-screen display is not the only way QC Weigh displays production data. At an interval that you choose, the software will generate a .PDF formatted report organized by product line, sample number, and product. This report will arrive in your e-mail inbox, delivering your company’s QC data to your desktop or with a smart phone – the palm of your hand. These QC control charts are a valuable snapshot of production performance for that day.

Quality Control Data That You Can Trust
Quality control data is often collected the same way it has been since the beginning of the industrial revolution, using pen or pencil and paper. While this method is easy to perform, it’s known to be inaccurate and the pages and pages of hand scrawled characters, make it almost impossible to spot patterns and pinpoint manufacturing problems. Quite often, handwritten records show that the product is always the same weight, when in reality that is impossible. Missed weighments mean that production equipment is not being adjusted to keep products in tolerance. These quality issues, part of the overall Cost of Poor Quality (CoPQ), can quickly add up to 5-30% of a company’s gross sales. Inaccurate QC forms make the managing and understanding of how to improve product quality an impossible task. Increase your plant’s profi ts with accurate digital records captured and archived by QC Weigh.

Easy to Configure and Use
Configuring QC Weigh and the 2200CW Scale is an almost effortless task thanks to the drop-down menus and easy to understand program prompts. Product parameters for each product and scale operator IDs are entered into QC Weigh. Each product has parameters for checkweigh tolerances, product description, ID, number of weighments, and time between samples. The product data and scale operator IDs are downloaded into the 2200CW Checkweigher that is connected to your Local Area Network (LAN) via Ethernet or Wireless Ethernet. QC Weigh can be installed on Windows PC or a network server. If it’s installed on PC, the standard database can be installed on a network server that is backed up on a regular interval.

During the manufacturing process, the employee responsible for sampling product weight is prompted to enter the product ID and their operator ID. Requiring operator IDs keeps the employee accountable for taking QC weight samples at the predetermined intervals. Management can use these records to track and evaluate employee work performance. When the scale operator logs in, the scale displays the seconds until the next weight sample is required. Once the scale timer reaches zero, the large red LED display will read LATE. In a noisy or busy work environment, the 2200CW can be equipped with an optional external alarm, the scale operator will be notifi ed with a sound or red light tower. For processes requiring multiple samples, the employee is prompted through the process of weighing each sample.

Provides a Fast Return on Investment
Your company will benefi t from a rapid return on investment with QC Weigh. Affordably priced, QC Weigh detects production issues that can have a negative effect on the bottom line. By addressing these issues, the additional profi ts quickly pay for the cost of QC Weigh and the scale equipment. That payback can be as quick as one month. QC Weigh offers the most economical way to meet a company’s needs for quick information on quality, costs, and variables in the manufacturing process.

Discover More about QC Weigh
Call us today at 800-832-0055 to find out how your company can benefit from the QC Weigh quality control system. A Doran Scale representative can arrange to have a demonstration of QC Weigh and walk you through all the features and share with you how others have used QC Weigh to increase their profi ts by improving product quality and reducing manufacturing costs.